Cable wire insertion verification

Abstract

To provide a method for verifying correct cable wire insertion into a connector housing.SOLUTION: The method includes, at an insertion verification system (400), receiving a vibration signal (404) from a vibration sensor (402). The vibration signal (404) represents vibration caused by insertion of a cable wire into a cable cavity of a cable connector housing. The vibration signal (404) is input to an insertion verification model (406) trained to evaluate whether input vibration signals are consistent with correct cable wire insertion. The insertion verification model (406) outputs an indication (408) that the vibration signal (404) is consistent with correct insertion of the cable wire into the cable cavity.SELECTED DRAWING: Figure 4A

Description

[Technical Field]

[0001]

[0001] The present invention relates generally to the construction of cable connectors, and more particularly to computer evaluation of vibration signals to verify correct cable wire insertion into a connector housing. [Background technology]

[0002]

[0002] Various types of cable connectors are often used to conductively (or optically) couple one cable to another and / or one cable to an electronic device for the transmission of data and / or power. In some embodiments, such connectors include one or more cable wires that are inserted into corresponding cable cavities in a connector housing. The size and shape of the connector housing, as well as the number and distribution of cable cavities contained within the connector housing, can vary from scenario to scenario, depending on the purpose of the cable connector. Summary of the Invention

[0003] This summary is not an extensive overview of the specification. It is not intended to identify key or critical elements of the specification or to delineate any scope of particular embodiments or any claims of the specification. Its sole purpose is to present some concepts of the specification in a simplified form as a prelude to the more detailed description that is presented in the present disclosure.

[0004] A method for verifying cable wire insertion includes receiving, in an insertion verification system, a vibration signal from a vibration sensor. The vibration signal represents vibrations caused by insertion of a cable wire into a cable cavity of a cable connector housing. The vibration signal is input to an insertion verification model trained to evaluate whether the input vibration signal is consistent with correct cable wire insertion. The insertion verification model outputs an indication that the vibration signal is consistent with correct cable wire insertion into the cable cavity.

[0005]

[0005] The features, functions, and advantages discussed may be realized individually in various embodiments or may be combined in yet other embodiments, further details of which can be understood by reference to the following description and drawings. [Brief explanation of the drawings]

[0006] [Figure 1]

[0006] An exemplary cable connector is shown schematically, including a cable connector housing and a cable wire. [Figure 2]

[0007] 1 illustrates an exemplary method for verification of cable wire insertion. [Figure 3]

[0008] 10A-10C are schematic diagrams illustrating the use of a cable insertion tool for inserting cable wires into a cable connector housing, the cable insertion tool including a vibration sensor; [Figure 4A]

[0009] 10 illustrates a schematic diagram of verification of cable wire insertion based on vibration signals; [Figure 4B] 10 illustrates a schematic diagram of verification of cable wire insertion based on vibration signals; [Figure 4C] 10 illustrates a schematic diagram of verification of cable wire insertion based on vibration signals; [Figure 5A]

[0010] 10A and 10B illustrate the insertion of cable wires into a cable cavity of a cable connector housing. [Figure 5B] 10A and 10B illustrate the insertion of cable wires into a cable cavity of a cable connector housing. [Figure 5C] 10A and 10B illustrate the insertion of cable wires into a cable cavity of a cable connector housing. [Figure 6]

[0011] 10A-10C schematically illustrate the use of a fixture to hold a cable connector housing in place, the fixture including a vibration sensor. [Figure 7]

[0012] 1 illustrates a schematic diagram of an exemplary computing system. DETAILED DESCRIPTION OF THE INVENTION

[0007]

[0013] Construction of cable connectors typically involves one or more steps in which individual cable wires are inserted into cable cavities in the connector housing. Such insertion may be performed manually, such as by a human operator, and / or automatically, such as via a suitable machine or robotic insertion system. In either case, however, cable wire insertion can be inconsistent and prone to error. Furthermore, manual inspection of connector housings during manufacturing can be tedious and time-consuming, and may not always detect cable insertion errors.

[0008]

[0014] For example, during the assembly process, cable wires typically must be fully inserted into connector housings to securely hold the cable wires in place within the connector housing and provide a stable connection with any electronic components, other cables / connectors, etc., to which the cable wires are connected via the cable connector. However, due to the physical characteristics of the wires and housings, as well as variability associated with manual assembly, consistently achieving full insertion can be difficult. Furthermore, insufficient insertion may not be apparent, especially if the cable wires fall slightly short of full insertion. Such a situation can lead to an incomplete electrical (and / or optical) connection, potentially resulting in downstream errors or failures caused by intermittent signal transmission.

[0009]

[0015] Accordingly, the present disclosure is directed to an insertion verification system used to monitor the insertion of cable wires into a cable connector housing and automatically evaluate whether such cable wires are inserted correctly. This may include, for example, determining whether the cable wires are inserted deep enough into the cable cavity (e.g., deep enough to engage a retention feature) and / or determining whether the correct type of cable contact (e.g., shape, size) is inserted into the cable cavity. Upon detecting correct insertion, the system may output an indication of correct insertion to a human operator and / or an automated assembly system. For example, the insertion verification system may illuminate an indicator light, play an audio alert, provide tactile feedback, output a computer-readable indication, etc. to confirm correct cable insertion.

[0010]

[0016] Specifically, the techniques described herein use vibration analysis and machine learning to detect proper insertion of cable wires into a cable connector housing. When a cable wire is inserted into a connector housing, the interaction between the cable wire and the cable cavity results in vibrations. The vibrations are captured by a vibration sensor and provided to an insertion verification model. The vibration sensor may, for example, be integrated into a cable insertion tool used for the insertion process and / or a fixture that holds the connector housing in place. The captured vibrations are converted into electrical vibration signals. The electrical vibration signals are subsequently analyzed by the insertion verification model. The model is trained based on multiple training examples (e.g., vibration signals labeled as corresponding to either correct or incorrect insertion) to evaluate whether an input vibration signal provided during inference corresponds to correct cable insertion. Based on the model's output, the system can provide an indication of correct cable wire insertion. In this manner, the present disclosure advantageously provides an accurate, automated solution for verifying correct insertion of cable wires. This solution reduces the risk of connection failure due to insufficient insertion and reduces the human effort associated with manual insertion verification.

[0011]

[0017] The insertion of cable wires into a connector housing is illustrated schematically with reference to FIG. 1 , which shows an exemplary cable connector 100. The cable connector includes a connector housing 102. The connector housing 102 includes multiple cable cavities. During assembly of the cable connector, multiple cables may be inserted into the multiple cable cavities. Some cable cavities are labeled in FIG. 1 as cable cavity 104. Additionally, FIG. 1 shows two different cable wires 106A and 106B. The cable wire 106A is fully inserted into the connector housing. However, the cable wire 106B is not fully inserted into the connector housing. Due to the incomplete insertion of the cable wires, a portion of the cable contact 108 attached to the cable wire 106B is visible.

[0012]

[0018] It will be understood that the specific components shown in FIG. 1 , as well as those shown in FIGS. 2-7 described herein, are greatly simplified for purposes of explanation. The size, shape, and specific appearance of the components shown in FIGS. 1-7 are non-limiting and are not drawn to scale. Furthermore, it will be understood that the components shown in FIGS. 1-7 may be constructed from any suitable materials. For example, the connector housing, housing retainer, cable wires, cable contacts, and other components described herein may be constructed from any suitable combination of plastic and / or metal, as non-limiting examples.

[0013]

[0019] While two different cable wires are shown in the example of Figure 1, it will be understood that any suitable number of different cable wires may be inserted into the connector housing. For example, the number of inserted cable wires may be equal to or less than the number of cable cavities in the connector housing. In other words, it will be understood that the specific configuration shown in Figure 1 is non-limiting, and that the techniques described herein may be applicable to cable connectors used to connect any suitable number of cable wires to each other and / or to an electronic device, such as a printed circuit board (PCB).

[0014]

[0020] This disclosure focuses primarily on electrically conductive cables used to transmit power and / or data, however, in some embodiments, the cable connectors described herein may be used with cable wires that are not electrically conductive but include other suitable transmission media, such as fiber optic cables.

[0015]

[0021] As used herein, "cable wire" includes a length of material (e.g., copper wire, optical fiber) used for the transmission of data and / or power that is often covered with a protective material (e.g., plastic or rubber insulation, grounded shielding). In other words, the term "cable wire" often refers herein not just to the conductive (e.g., copper) or non-conductive (e.g., optical fiber) core of a cable, but may also refer to any coating, insulation, and / or shielding added to the core.

[0016]

[0022] A "cable" includes one or more different cable wires. If a cable includes only one cable wire, the terms "cable wire" and "cable" may be used interchangeably. However, in some examples, a cable includes two or more cable wires bundled together. For example, in some embodiments, a cable is a multi-conductor cable including two or more cable wires (e.g., different conductive copper wires, each covered with its own insulating cable jacket) and bundled together with additional insulation and / or shielding to form the multi-conductor cable. In some embodiments, a "cable" is a shielded twisted pair cable. In this case, different cable wires include pairs of twisted conductors protected by an insulating jacket. The twisted pairs are themselves bundled together and surrounded by additional shielding and / or insulation to form a shielded twisted pair cable. If a cable includes two or more different cable wires, the different cable wires can each be inserted into a different cable cavity of the connector housing.

[0017]

[0023] Generally, there is a correspondence between different specific cable wires and the cable cavities into which they are inserted. For example, different specific cable wires may have different purposes (e.g., to transmit power, to transmit data, to complete a ground connection) and therefore may be inserted into different specific cable cavities. A final connector may then be used to couple the cable wires to the correct downstream components (e.g., ground points, input / output lines, power inlets). In some cases, different cable wires have different, distinguishable appearances. For example, the cable wires may have different sizes (e.g., gauges), use different colors or types of insulating / protective jackets, use different materials for the cable wire cores (e.g., different conductive metals or non-conductive materials), and / or differ in any other suitable manner.

[0018]

[0024] In the embodiment of FIG. 1 , conductive cable contacts 108 are attached to the ends of cable wires 106B. However, in general, the ends of cable wires may be processed in any suitable manner. For example, in some embodiments, conductive contacts may be attached to cable wires. If so, such contacts may have any suitable size and shape. In some cases, different types of conductive contacts may be attached to different cable wires inserted into the same connector housing. In some embodiments, the cable wires need not include conductive contacts. Rather, for example, the cable wires may terminate at exposed lengths of cable wire cores or in any other suitable manner.

[0019]

[0025] Each cable cavity of the connector housing is sized and shaped for insertion of a cable wire. As shown, cable wires 106A and 106B are inserted into respective cable cavities of the connector housing. The cable cavities have any suitable size based on the size of the cable intended for insertion into the cable cavity. In some embodiments, the same connector housing may include different cable cavity sizes intended for insertion of cable wires having different sizes (e.g., different wire gauges).

[0020]

[0026] In some cases, the cable cavity is sized to receive an insulating jacket surrounding a core of cable wire (e.g., copper wire or fiber optic material), so that a length of insulated cable is inserted into the connector housing. In other embodiments, the insulating jacket can be cut away, so that only the cable core is inserted into the connector housing.

[0021]

[0027] Any suitable length of cable wire may be inserted into the connector housing. Generally, the cable wire is inserted deep enough into the connector housing to allow transmission of data and / or power between the cable wire and any component, such as another cable wire and / or electronic device, that is coupled to the connector housing. Additionally or alternatively, the cable wire may be inserted deep enough so that a retention feature within the connector housing holds the cable wire in place.

[0022]

[0028] However, as discussed above, in some cases, such insertion may be prone to insertion errors. For example, cable wires may not be inserted deep enough into their respective cable cavities and / or may be inserted into the incorrect cable cavities. Manual inspection and verification of cable wire insertion may be tedious and time-consuming. Accordingly, FIG. 2 illustrates an exemplary method 200 for verifying cable wire insertion. Steps of method 200 may be initiated, terminated, and / or repeated at any appropriate time and in response to any appropriate conditions. Method 200 is described primarily as being performed by an insertion verification system, which includes a controller. The controller executes software instructions for implementing a machine learning system for vibration analysis. However, steps of method 200 may be performed by any suitable computing system of one or more computing devices, and any computing device performing steps of method 200 may have any suitable capabilities, hardware configuration, and form factor. In some embodiments, method 200 is performed by computing system 700, described below with reference to FIG. 7.

[0023]

[0029] At 202, method 200 receives a vibration signal from a vibration sensor in an insertion verification system. The vibration signal represents vibrations caused by the insertion of a cable wire into a cable cavity of a cable connector housing. This is shown generally with respect to FIGS. 3 and 4A-4C. FIG. 3 generally illustrates another exemplary cable connector 300 being assembled. Cable connector 300 includes a connector housing 302, which itself includes multiple cable cavities 304. In this example, a cable wire 306 is in the process of being inserted into one of the cable cavities.

[0024]

[0030] Notably, in this embodiment, a cable insertion tool 308 is used during insertion of the cable wire 306 into the connector housing 302. In one exemplary scenario, a human operator may perform the initial insertion of the cable wire by hand, for example, by pushing the cable contacts and length of the cable wire into the connector housing. After this initial insertion, the human operator may use the cable insertion tool 308 to push additional lengths of the cable wire into the connector housing until the cable wire has been inserted deep enough to engage the retention features of the connector housing (and / or until any other suitable insertion conditions are met).

[0025]

[0031] It will be understood that this scenario is non-limiting. For example, in other embodiments, the entire insertion of the cable wires may be performed using a cable insertion tool (without initial manual insertion), or the cable insertion may be performed without the use of a cable insertion tool. For example, as will be described in more detail below, insertion detection techniques may, in some cases, be used in scenarios where a fixture holds the connector housing in place and the vibration detection capabilities described herein may be implemented at least in part via a vibration sensor installed within the fixture. In some embodiments, the vibration sensor may be included within the cable insertion tool in addition to a fixture that may be used to hold the connector housing. In some embodiments, the cable insertion may be performed by an automated system (e.g., a cable insertion robot) without the need for a human operator to perform the insertion.

[0026]

[0032] In the embodiment of FIG. 3 , the cable insertion tool 308 includes a vibration sensor 310. In other words, in this embodiment, the vibration sensor is integrated into the cable insertion tool used to insert cable wires into the cable cavity of the cable connector housing. Vibrations thereby propagate through the body of the cable insertion tool and reach the vibration sensor. The vibration sensor takes the form of any suitable computer hardware component that can be used to detect vibrations caused by the insertion of cable wires into the cable cavity. For example, the vibration sensor may take the form of any suitable device configured to convert mechanical vibrations into an electrical signal. In some embodiments, the vibration sensor includes two or more different components, each configured to detect vibrations. As non-limiting examples, the vibration sensor may include a piezoelectric sensor (e.g., converting mechanical stresses induced by vibratory motion into an electrical signal via the piezoelectric effect), an accelerometer (e.g., measuring acceleration forces that displace a mass from its neutral position and converting this movement into an electrical signal), and / or a microphone (converting sound waves into an electrical signal via the movement of a diaphragm in response to changes in air pressure). As one non-limiting example, an electret microphone may be used.

[0027]

[0033] 3, only one vibration sensor is shown, it will be understood that this is non-limiting. Rather, a cable insertion tool used for cable wire insertion, a fixture used to hold the connector housing, and / or any other suitable structure involved in the cable connector assembly process may include any suitable number of different vibration sensors. In some cases, a greater number of different vibration sensors (e.g., detecting vibrations using multiple different modalities) may improve the sensitivity and accuracy of the insertion verification system.

[0028]

[0034] In FIG. 3 , the vibration sensor is communicatively coupled to an insertion verification system 312. An “insertion verification system” takes the form of any suitable computer logic hardware configured to execute instructions encoded in software, firmware, and / or hardware to thereby evaluate vibration signals and verify correct cable wire insertion. In some embodiments, the insertion verification system is implemented as a computing system 700, described below with respect to FIG. 7 . As will be described in more detail below, the insertion verification system can be used to implement machine learning insertion verification models. In cases where an automated system is used for the insertion of cable wires into the connector housing, such an automated system may, in some cases, be controlled by or otherwise communicatively coupled to the insertion verification system.

[0029]

[0035] In this example, the insertion verification system is shown separate from the cable insertion tool. For example, the cable insertion tool may be communicatively coupled to the insertion verification system using an appropriate cable and / or wireless data communication channel. Additionally or alternatively, aspects of the insertion verification system may be integrated into the same housing as the cable insertion tool.

[0030]

[0036] In any case, during insertion of the cable wire into the cable cavity, contact between the cable wire and the cable cavity causes vibrations that are detected by the vibration sensor. The vibration sensor then outputs a vibration signal to the insertion verification system. This is shown schematically with respect to FIG. 4A . FIG. 4A shows an exemplary insertion verification system 400 communicatively coupled to a vibration sensor 402. From the vibration sensor 402, the insertion verification system 400 receives a vibration signal 404. As will be described in more detail below, the vibration signal is input to an insertion verification model 406. The insertion verification model 406 then outputs an indication 408 of correct cable wire insertion. In this example, the insertion verification system further includes a signal detection system 410 and an analog-to-digital converter (ADC) 412, which will be described in more detail below.

[0031]

[0037] In some examples, vibration signals may be received continuously while the vibration sensor and insertion verification are powered on. For example, when noise occurs in the surrounding environment, people and / or machines move around in a room, or an assembly process is occurring nearby, ambient vibrations may be detected by the vibration sensor and reported to the insertion verification system. In some examples, it may not be desirable to continuously input such ambient vibration signals into the insertion verification model. For example, this may unnecessarily consume computational resources of the insertion verification system.

[0032]

[0038] 2, at 204, method 200 optionally includes detecting, via a signal detection system of the insertion verification system, that the vibration has exceeded a signal amplitude threshold. In FIG. 4A, the insertion verification system includes signal detection system 410. Signal detection system 410 receives vibration signal 404. The signal detection system is implemented as any suitable combination of computer hardware, software, and / or firmware usable to evaluate the relative strength of the input vibration signal.

[0033]

[0039] As one non-limiting example, the signal detection system may include a signal processor. Further, the signal processor may perform any suitable steps in addition to or instead of determining whether the vibration signal exceeds a signal amplitude threshold. For example, in some embodiments, the signal processor may be used to filter frequencies from the vibration signal, amplify the vibration signal, reduce noise in the vibration signal, etc.

[0034]

[0040] FIG. 4B schematically illustrates the use of the signal detection system 410 in more detail. Specifically, FIG. 4B shows an analog representation 414 of the vibration signal 404. The signal detection system evaluates whether the vibration signal exceeds a signal amplitude threshold 416. Upon determining that the vibration signal exceeds the signal amplitude threshold, the signal detection system outputs the vibration signal to the insertion verification model. Alternatively, if the vibration signal does not exceed the signal amplitude threshold, the signal detection system may refrain from outputting the vibration signal to the insertion verification model. In this manner, the insertion verification model is only used to evaluate vibration signals that exceed the signal amplitude threshold. This beneficially reduces the waste of computational resources when the insertion verification model is only used to evaluate vibration signals that are likely to correspond to the insertion of a cable wire into a cable cavity during assembly of the cable connector.

[0035]

[0041] 4B, the vibration signal is received at the insertion verification system as an analog representation of the underlying vibration. For example, the vibration signal may be received as the direct output of a piezoelectric sensor, an accelerometer, a microphone, and / or other suitable type of vibration sensor. In such cases, the analog representation may be converted to a digital representation before inputting the vibration signal into the insertion verification model.

[0036]

[0042] 2, at 206, method 200 optionally includes converting an analog representation of the vibration signal to a digital representation using an analog-to-digital converter (ADC) before inputting the vibration signal to the insertion validation model. In the example of FIG. 4A, the vibration signal is received at ADC 412. ADC 412 converts the vibration signal to a digital representation before inputting the vibration signal to the insertion validation model.

[0037]

[0043] The operation of the ADC 412 is illustrated in more detail generally with respect to FIG. 4C. Specifically, FIG. 4C again shows an analog representation 414 of the vibration signal 404. The ADC then converts the analog representation to a digital representation 418, where the underlying vibration is encoded through a stream of digital bits. This digital representation is then input to the insertion verification model 406.

[0038]

[0044] It will be appreciated that analog-to-digital conversion need not be performed by the insertion verification system. For example, in some embodiments, the vibration signal may first be converted to a digital representation by a vibration sensor or another suitable computer system before the vibration signal is received at the insertion verification system. Thus, in some embodiments, the insertion verification system need not include an ADC, as shown in FIGS. 4A and 4C.

[0039]

[0045] Returning briefly to FIG. 2 , at 208, method 200 includes inputting a vibration signal into an insertion verification model. As described above, the insertion verification model is trained to evaluate whether the input signal is consistent with correct wire insertion. Such training is based on a dataset including multiple training examples. The dataset may include examples of both correct and incorrect insertions, capturing a wide variety of insertion scenarios and conditions (e.g., different insertion distances, speeds, amount of insertion force used, type of cable contact used) to ensure the model can generalize well. Each training example may be labeled according to whether it corresponds to a correct or incorrect insertion.

[0040]

[0046] The insertion verification model may take any suitable form using any suitable machine learning (ML) and / or artificial intelligence (AI) model. As non-limiting examples, deep learning models such as decision trees, support vector machines (SVMs), neural networks, or convolutional neural networks (CNNs) may be suitable for implementing an insertion verification system.

[0041]

[0047] In some examples, the insertion verification system may maintain multiple different insertion verification models. For example, different models may be separately trained for different connector housings, different types of cable contacts, different types of insertion techniques (e.g., manual insertion by a human operator versus automated insertion via an assembly machine), etc. In some examples, the model used to evaluate a given vibration signal may be selected by a human operator (e.g., by identifying the type of cable connector being assembled) and / or may be automatically determined based on sensor data. In some examples, the same vibration signal may be provided to two or more different machine learning models. Each of the two or more different machine learning models may output an indication of whether the vibration signal is consistent with correct insertion according to the model's respective training.

[0042]

[0048] As discussed above, "correct" insertion of a cable wire may be determined according to any suitable criteria. In some embodiments, correct cable wire insertion includes inserting the cable wire deep enough into the cable cavity to engage a retention feature that resists removal of the cable wire from the cable cavity. This is illustrated schematically with respect to FIGS. 5A-5C. Specifically, FIG. 5A schematically illustrates a cable wire 500 having a cable contact 502 attached to a distal end of the cable wire. In FIG. 5A, as shown in cross section, the cable wire and cable contact are in the process of being inserted into a cable cavity 504. It will be appreciated that the cable cavity 504 may be one of multiple cable cavities in a connector housing, for example, as shown in FIGS. 1 and 3.

[0043]

[0049] In Figure 5A, the cable cavity includes a retention mechanism 506. In this embodiment, the retention mechanism is implemented as a pair of clips. The pair of clips grip a portion of the cable contact when the portion of the cable contact is inserted deep enough into the cable cavity, thereby resisting retraction of the cable contact from the cable cavity. This is shown schematically in Figures 5B and 5C. In Figure 5B, the cable wire is partially inserted into the cable cavity. This is because the retention clip has opened and partially inserted the cable contact. However, the cable contact has not been inserted deep enough to fully engage the retention feature. In contrast, in FIG. 5C, full insertion of the cable connector has been achieved. Therefore, the geometry of the cable contact and cable cavity resists further insertion of the cable contact. Additionally, the location of the retention feature relative to the cable connector resists removal of the cable contact from the cable cavity.

[0044]

[0050] When this configuration is achieved, movement of the cable contact and retention mechanism can cause a noticeable vibration corresponding to full insertion of the cable wire into the cable cavity. This noticeable vibration can be recognized by an insertion verification system. This vibration can be distinguished from other vibrations caused by the insertion of the cable wire into the cable cavity. For example, vibrations occurring during the condition shown in FIG. 5B can be classified by the insertion verification system as not corresponding to correct insertion of the cable wire.

[0045]

[0051] It will be understood that the specific scenarios illustrated in Figures 5A-5C are non-limiting. For example, the specific shape of the cable contact, the specific shape of the cable cavity, and the manner in which the retention mechanism is implemented may vary from embodiment to embodiment. In general, the retention mechanism may use any suitable force to resist removal of the cable contact from the cable cavity. For example, the retention mechanism may use friction, adhesion, suction, magnetism, etc.

[0046]

[0052] Additionally, additional or alternative criteria may be used to determine whether a cable wire is correctly inserted. For example, in some embodiments, the type of cable contact (e.g., size, shape), the type of cable wire (e.g., width, material properties), the particular cable cavity into which the cable wire is inserted, the type of cable connector into which the cable contact is inserted, etc. may each affect the vibration signals detected at the vibration sensor. Thus, as another example, correct cable contact insertion may include determining that the cable wire includes the intended cable contact type. This may catch instances where a human operator attempts to insert an incorrect cable wire into a given cable cavity, for example, if the cable wire has a different type of cable contact than expected.

[0047]

[0053] Returning briefly to FIG. 2 , at 210, method 200 includes outputting an indication from the insertion verification model that the vibration signal is consistent with correct insertion of the cable wire into the cable cavity. Such an indication may take any suitable form. As non-limiting examples, outputting the indication of correct insertion may include any or all of: illuminating an indicator light, playing an audible insertion confirmation, activating a tactile feedback system, displaying text on a computer display, outputting data confirmation to an automated assembly system, and / or providing any other suitable type of correct insertion feedback.

[0048]

[0054] Returning briefly to Figure 3, in this example, the cable insertion tool 308 includes various feedback systems that may be used to provide indications of correct insertion to a human operator. It will be understood that this scenario is non-limiting and that any suitable combination of one or more suitable feedback systems may be used. Furthermore, such feedback systems may be integrated into any suitable device or component in addition to or instead of the cable insertion tool.

[0049]

[0055] 3, the cable insertion tool includes a tactile feedback system 314. Upon detecting correct insertion, the insertion verification system may activate the tactile feedback system to provide confirmation to the human operator holding the cable insertion tool. Similarly, in this embodiment, the cable insertion tool includes an audio speaker 316. The audio speaker 316 may be activated to play an audio confirmation of insertion. The cable insertion tool 308 further includes an indicator light 318. The indicator light 318 may be illuminated to indicate correct cable wire insertion.

[0050]

[0056] This disclosure has thus far primarily focused on the following scenario: the cable wire is inserted correctly, and therefore the insertion verification system outputs an indication of correct insertion. However, it will be appreciated that the insertion verification system may also or alternatively output an indication when it is determined that a particular vibration signal does not correspond to correct insertion of the cable wire. For example, an indicator light may be illuminated in a different color and / or a different indicator light may be illuminated. In lieu of an audible insertion confirmation, an audible error indication may be played. A tactile feedback system may be activated to provide a tactile pattern indicating an unsuccessful insertion. Error text may be displayed on a screen. An error report may be output to an automated system, etc.

[0051]

[0057] In some cases, the indication of incorrect insertion may identify the manner in which the insertion failed. For example, the indication of incorrect insertion may identify whether the cable wire was inserted an insufficient distance, whether the wrong type of cable contact was inserted, whether the cable wire was inserted into the wrong cavity, and / or any other detectable fault condition. Such information may be identified in any suitable manner, such as via any or all of the feedback systems described above.

[0052]

[0058] This disclosure has thus far focused primarily on the following scenario: aspects of the insertion verification system are implemented in conjunction with a cable insertion tool (e.g., cable insertion tool 308) used to insert cable wires into a connector housing. However, as noted above, aspects of the insertion verification system may also or alternatively be implemented in conjunction with a fixture used to hold the connector housing in place. In other words, according to the techniques described herein, a vibration sensor may be integrated into the insertion tool and / or into the fixture, and either or both of these sensor systems may be used in any suitable combination. For example, an insertion tool including a vibration sensor may be used without a fixture, a fixture with a vibration sensor may be used without an insertion tool, an insertion tool and a fixture may be used together, with only one including a vibration sensor, or an insertion tool and a fixture may be used together, with both including vibration sensors.

[0053]

[0059] This is illustrated diagrammatically with respect to Figure 6, which diagrammatically illustrates another exemplary cable connector 600 being assembled. The cable connector 600 includes a connector housing 602. The connector housing 602 itself includes a plurality of cable cavities 604. In this example, a cable wire 606 is in the process of being inserted into one of the cable cavities. Furthermore, in this example, the connector housing is held in place by a jig 608. It will be appreciated that the particular design and appearance of the jig 608 in Figure 6 is non-limiting, and that in general, a "jig" may take the form of any suitable structure that can be used to securely hold the connector housing in place while the cable wire is being inserted.

[0054]

[0060] In this embodiment, a vibration sensor 610 is integrated into the fixture 608. In other words, in this embodiment, the vibration sensor is integrated into the fixture that holds the cable connector housing in place. Vibrations thereby propagate through the body of the fixture and reach the vibration sensor. Similar to the embodiment described above with respect to FIG. 3 , the fixture may include any suitable number of one or more different vibration sensors. Furthermore, such vibration sensors may have any suitable distribution within the fixture and / or other components included within the cable connector assembly. In this embodiment, the vibration sensor is communicatively coupled to an insertion verification system 612. The insertion verification system 612 can be used to evaluate whether a vibration signal captured by the vibration sensor corresponds to a correct cable wire insertion. Upon detecting a correct insertion, the insertion verification system can activate one or more feedback systems, as described above. For example, in FIG. 6 , the fixture includes a tactile feedback system 614, an audio speaker 616, and an indicator light 618.

[0055]

[0061] The methods and processes described herein may be coupled to the computing system of one or more computing devices. In particular, such methods and processes may be implemented as an executable computer application program, a network-accessible computing service, an application programming interface (API), a library, or a combination of the above and / or other computing resources.

[0056]

[0062] 7 illustrates a simplified representation of an exemplary computing system 700 configured to provide any or all of the computing functionality described herein. Computing system 700 may take the form of one or more network-accessible devices, personal computers, server computers, portable computing devices, and / or other computing devices.

[0057]

[0063] Computing system 700 includes a logic subsystem 702 and a storage subsystem 704. Computing system 700 may optionally include a display subsystem 706, an input subsystem 708, a communication subsystem 710, and / or other subsystems not shown in FIG.

[0058]

[0064] The logic subsystem 702 includes one or more physical devices configured to execute instructions. For example, the logic subsystem may be configured to execute instructions, which are part of one or more applications, services, programs, or other logical structures. The logic subsystem may include one or more hardware processors configured to execute software instructions. Additionally or alternatively, the logic subsystem may include one or more hardware or firmware devices configured to execute hardware or firmware instructions. The processors of the logic subsystem may be single-core or multi-core, and the instructions executed by the processors may be configured for sequential, parallel, and / or distributed processing. Individual components of the logic subsystem may optionally be distributed across two or more separate devices. These devices may be remotely located and / or configured for coordinated processing. Aspects of the logic subsystem may be virtualized and executed by remotely accessible networked computing devices configured as a cloud computing configuration.

[0059]

[0065] The storage subsystem 704 includes one or more physical devices configured to temporarily and / or permanently store computer information, such as data and instructions, executable by the logic subsystem. When the storage subsystem includes two or more devices, these devices may be co-located and / or remotely located. The storage subsystem 704 may include volatile devices, non-volatile devices, dynamic devices, static devices, read / write devices, read-only devices, random access devices, sequential access devices, location-addressable devices, file-addressable devices, and / or content-addressable devices. The storage subsystem 704 may include removable and / or internal devices. When the logic subsystem executes instructions, the state of the storage subsystem 704 may be transformed, for example, to hold different data.

[0060]

[0066] The logic subsystem 702 and the storage subsystem 704 may be integrated into one or more hardware logic components, which may include program and application specific integrated circuits (PASICs / ASICs), program and application specific standard products (PSSPs / ASSPs), systems on a chip (SOCs), and complex programmable logic devices (CPLDs).

[0061]

[0067] The logic subsystem and storage subsystem may cooperate to instantiate one or more logic machines. As used herein, the term “machine” collectively refers to a combination of hardware, firmware, software, instructions, and / or any other components that cooperate to provide computer functionality. In other words, a “machine” is never an abstract idea but always has a concrete form. A machine may be instantiated by a single computing device, or a machine may include two or more subcomponents instantiated by two or more different computing devices. In some embodiments, a machine includes a local component (e.g., a software application executed by a computer processor) that cooperates with a remote component (e.g., a cloud computing service provided by a network of server computers). The software and / or other instructions that give a particular machine its functionality may optionally be stored as one or more unexecuted modules on one or more suitable storage devices.

[0062]

[0068] When included, the display subsystem 706 can be used to present a visual representation of the data maintained by the storage subsystem 704. This visual representation can take the form of a graphical user interface (GUI). The display subsystem 706 can include one or more display devices utilizing virtually any type of technology. In some implementations, the display subsystem can include one or more virtual, augmented, or mixed reality displays.

[0063]

[0069] When included, the input subsystem 708 may include or interact with one or more input devices. Input devices may include sensor devices or user input devices. Examples of user input devices include a keyboard, a mouse, a touchscreen, or a game controller. In some embodiments, the input subsystem may include or interact with selected natural user input (NUI) components. Such components may be integrated or peripheral, and input act transmission and / or processing may be handled on-board or off-board. Exemplary NUI components may include microphones for speech and / or voice recognition; infrared, color, stereo, and / or depth cameras for machine vision and / or gesture recognition; head trackers, eye trackers, accelerometers, and / or gyroscopes for motion detection and / or intent recognition.

[0064]

[0070] If included, communications subsystem 710 may be configured to communicatively couple computing system 700 with one or more other computing devices. Communications subsystem 710 may include wired and / or wireless communication devices compatible with one or more different communications protocols. Communications subsystem may be configured for communication over personal, local, and / or wide area networks.

[0065]

[0071] The present disclosure is presented by way of example and with reference to the associated drawings. Components, process steps, and other elements that may be substantially the same in one or more of the drawings are identified collectively and described with minimal repetition. It should be noted, however, that collectively identified elements may also differ to some extent. It should be further noted that some of the drawings are schematic and not to scale. Various drawing scales, aspect ratios, and numbers of elements shown in the drawings may be intentionally distorted to more clearly show particular features or relationships.

[0066]

[0072] In one embodiment, a method for verifying cable wire insertion includes receiving, in an insertion verification system, a vibration signal from a vibration sensor, the vibration signal representing vibrations caused by insertion of a cable wire into a cable cavity of a cable connector housing; inputting the vibration signal to an insertion verification model, the insertion verification model being trained to evaluate whether the input vibration signal corresponds to correct cable wire insertion; and outputting an indication from the insertion verification model that the vibration signal corresponds to correct insertion of the cable wire into the cable cavity. In this or any other embodiment, the vibration signal is received from the vibration sensor as an analog representation of the vibration, and the method further includes converting the analog representation to a digital representation using an analog-to-digital converter (ADC) before inputting the vibration signal to the insertion verification model. In this or any other embodiment, the vibration sensor is integrated into the cable insertion tool used to insert the cable wire into the cable cavity of the cable connector housing such that the vibration propagates through a body of the cable insertion tool and reaches the vibration sensor. In this or any other embodiment, the vibration sensor is integrated into the fixture that holds the cable connector housing in place such that the vibration propagates through a body of the fixture and reaches the vibration sensor. In this or any other embodiment, correct cable wire insertion includes inserting the cable wire deep enough into the cable cavity to engage a retention feature that resists removal of the cable wire from the cable cavity. In this or any other embodiment, correct cable wire insertion includes determining that the cable wire includes an intended cable contact type. In this or any other embodiment, the method further includes detecting that the vibration exceeds a signal amplitude threshold via a signal detection system of the insertion verification system before inputting the vibration signal into the insertion verification model. In this or any other embodiment, outputting the indication includes illuminating an indicator light.In this or any other embodiment, outputting the indication includes playing an audio confirmation of insertion. In this or any other embodiment, outputting the indication includes activating a tactile feedback system. In this or any other embodiment, the vibration sensor includes a piezoelectric sensor. In this or any other embodiment, the vibration sensor includes an accelerometer. In this or any other embodiment, the vibration sensor includes a microphone.

[0067]

[0073] In one embodiment, an insertion verification system includes a logic subsystem and a storage subsystem holding a set of instructions executable by the logic subsystem, the set of instructions, when executed by the logic subsystem, to perform the following: receive a vibration signal from a vibration sensor, the vibration signal representing vibrations caused by insertion of a cable wire into a cable cavity of a cable connector housing; input the vibration signal to an insertion verification model, the insertion verification model being trained to evaluate whether the input vibration signal is consistent with correct cable wire insertion; and output an indication from the insertion verification model that the vibration signal is consistent with correct insertion of the cable wire into the cable cavity. In this or any other embodiment, the vibration signal is received from the vibration sensor as an analog representation of the vibration, and the set of instructions is further executable to convert the analog representation to a digital representation using an analog-to-digital converter (ADC) before inputting the vibration signal to the insertion verification model. In this or any other embodiment, the vibration sensor is integrated into the cable insertion tool used to insert the cable wire into the cable cavity of the cable connector housing, such that the vibration propagates through a body of the cable insertion tool and reaches the vibration sensor. In this or any other embodiment, the vibration sensor is integrated into a fixture that holds the cable connector housing in place, such that the vibration propagates through a body of the fixture and reaches the vibration sensor. In this or any other embodiment, the set of instructions may be further executable to detect, via a signal detection system of the insertion verification system, that the vibration exceeds a signal amplitude threshold before inputting the vibration signal into the insertion verification model. In this or any other embodiment, outputting the indication may include one or more of illuminating an indicator light, playing an audible insertion confirmation, and activating a tactile feedback system.

[0068]

[0074] In one embodiment, a method for verifying cable wire insertion includes receiving, in an insertion verification system, a vibration signal from a vibration sensor, the vibration signal representing vibrations caused by insertion of a cable wire into a cable cavity of a cable connector housing, the vibration sensor being integrated into a cable insertion tool used to insert the cable wire into the cable cavity of the cable connector housing; inputting the vibration signal to an insertion verification model, the insertion verification model being trained to evaluate whether the input vibration signal is consistent with correct cable wire insertion; and outputting an indication from the insertion verification model that the vibration signal is consistent with insertion of the cable wire sufficiently deep into the cable cavity to engage a retention feature that resists removal of the cable wire from the cable cavity.

[0069]

[0075] It will be understood that the configurations and / or approaches described herein are exemplary in nature, and that these specific embodiments or examples should not be considered limiting, as numerous variations are possible. The specific routines or methods described herein may represent one or more of any number of processing strategies. As such, various operations illustrated and / or described may be performed in the order illustrated and / or described, in other orders, concurrently, or omitted. Similarly, the order of processes described above may be changed.

[0070]

[0076] The subject matter of the present disclosure includes all novel and non-obvious combinations and subcombinations of the various processes, systems, and configurations, as well as other features, functions, operations, and / or properties disclosed herein, and any and all equivalents thereof. [Explanation of symbols]

[0071] 100 Exemplary Cable Connector 102 Connector housing 104 Cable Cavity 106A, 106B Cable Wire 108 Cable Contacts 200 Exemplary Methods 202, 204, 206, 208, 210 method steps 300 Exemplary Cable Connector 302 Connector Housing 304 Cable Cavity 306 Cable Wire 308 Cable Insertion Tool 310 Vibration Sensor 312 Insertion Verification System 314 Tactile Feedback System 316 Acoustic Speaker 318 indicator light 400 Exemplary Insertion Verification System 402 Vibration Sensor 404 Vibration Signal 406 Insertion Validation Model 408 Correct Cable Wire Insertion 410 Signal Detection System 412 ADC 414 Analog Expression 416 Signal Amplitude Threshold 418 Digital Representation 500 Exemplary Cable Wire 502 Cable Contact 504 Cable Cavity 506 Retention mechanism 600 Exemplary Cable Connector 602 Connector Housing 604 Cable Cavity 606 Cable Wire 608 Jig 610 Vibration Sensor 612 Insertion Verification System 614 Tactile Feedback System 616 Acoustic Speaker 618 indicator light 700 Computing System 702 Logic Subsystem 704 Storage Subsystem 706 Display Subsystem 708 Input Subsystem 710 Communication Subsystem

Claims

1. A method (200) for verification of cable wire insertion, comprising: receiving (202) a vibration signal (404) from a vibration sensor (402) in an insertion verification system (400), the vibration signal (404) representing vibrations caused by insertion of a cable wire (306) into a cable cavity (304) of a cable connector housing (302); inputting (208) the vibration signal (404) into an insertion verification model (406), the insertion verification model (406) being trained to evaluate whether the input vibration signal is consistent with a correct cable wire insertion; and The method (200) includes outputting (210) from the insertion verification model (406) an indication (408) that the vibration signal (404) is consistent with correct insertion of the cable wire (306) into the cable cavity (304).

2. 2. The method of claim 1, wherein the vibration signal is received from the vibration sensor as an analog representation of the vibration, the method further comprising converting the analog representation to a digital representation using an analog-to-digital converter (ADC) before inputting the vibration signal to the insertion verification model.

3. 2. The method of claim 1, wherein the vibration sensor is integrated into a cable insertion tool used to insert the cable wire into the cable cavity of the cable connector housing such that the vibration propagates through a body of the cable insertion tool and reaches the vibration sensor.

4. 2. The method of claim 1, wherein the vibration sensor is integrated into a fixture that holds the cable connector housing in place such that the vibrations propagate through the body of the fixture and reach the vibration sensor.

5. 2. The method (200) of claim 1, wherein correct cable wire insertion comprises inserting the cable wire (306) deep enough into the cable cavity (304) to engage a retention feature (506) that resists removal of the cable wire (306) from the cable cavity (304).

6. The method (200) of claim 1, wherein correct cable wire insertion comprises determining that the cable wire (306) includes an intended cable contact type.

7. 2. The method of claim 1, further comprising detecting, via a signal detection system of the insertion verification system, that the vibration exceeds a signal amplitude threshold before inputting the vibration signal into the insertion verification model.

8. 10. The method of claim 1, wherein outputting the indication comprises illuminating an indicator light.

9. 10. The method of claim 1, wherein outputting the indication comprises playing an audible confirmation of the insertion.

10. 10. The method of claim 1, wherein outputting the indication comprises activating a tactile feedback system.

11. The method of claim 1 , wherein the vibration sensor comprises a piezoelectric sensor.

12. The method of claim 1 , wherein the vibration sensor comprises an accelerometer.

13. The method of claim 1 , wherein the vibration sensor comprises a microphone.

14. a logic subsystem (702); and an insertion verification system (400) comprising a storage subsystem (704) holding a set of instructions executable by the logic subsystem (702), the set of instructions, when executed by the logic subsystem (702), receiving a vibration signal (404) from a vibration sensor (402), the vibration signal (404) representing vibrations caused by insertion of a cable wire (306) into a cable cavity (304) of a cable connector housing (302); inputting the vibration signal (404) into an insertion verification model (406), the insertion verification model (406) being trained to evaluate whether the input vibration signal is consistent with a correct cable wire insertion; and and outputting, from the insertion verification model (406), an indication (408) that the vibration signal (404) is consistent with correct insertion of the cable wire (306) into the cable cavity (304).

15. 15. The insertion verification system of claim 14, wherein the vibration signal is received from the vibration sensor as an analog representation of the vibration, and the set of instructions is further executable to convert the analog representation to a digital representation using an analog-to-digital converter (ADC) before inputting the vibration signal to the insertion verification model.

16. 15. The insertion verification system (400) of claim 14, wherein the vibration sensor (402) is integrated into the cable insertion tool (308) used to insert the cable wire (306) into the cable cavity (304) of the cable connector housing (302) such that the vibration propagates through a body of the cable insertion tool (308) and reaches the vibration sensor (402).

17. 15. The insertion verification system (400) of claim 14, wherein the vibration sensor (402) is integrated into a fixture (608) that holds the cable connector housing (602) in place such that the vibrations propagate through a body of the fixture (608) and reach the vibration sensor (402).

18. 15. The insertion verification system (400) of claim 14, wherein the set of instructions is further executable to detect, via a signal detection system (410) of the insertion verification system (400), that the vibration exceeds a signal amplitude threshold before inputting the vibration signal (404) into the insertion verification model (406).

19. 15. The insertion verification system of claim 14, wherein outputting the indication comprises one or more of illuminating an indicator light, playing an audible insertion confirmation, and activating a tactile feedback system.

20. A method (200) for verification of cable wire insertion, comprising: receiving a vibration signal (404) from a vibration sensor (402) in an insertion verification system (400), the vibration signal (404) representing vibrations caused by insertion of a cable wire (306) into a cable cavity (304) of a cable connector housing (302), the vibration sensor (402) being integrated into a cable insertion tool (308) used to insert the cable wire (306) into the cable cavity (304) of the cable connector housing (302); inputting the vibration signal (404) into an insertion verification model (406), the insertion verification model (406) being trained to evaluate whether the input vibration signal is consistent with a correct cable wire insertion; and The method (200) includes outputting an indication (408) from the insertion verification model (406) that the vibration signal (404) is consistent with insertion of the cable wire (306) sufficiently deep into the cable cavity (304) to engage a retention feature (506) that resists removal of the cable wire (306) from the cable cavity (304).

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